Bobbin for a transformer, transformer and method for manufacturing a transformer

Abstract

A bobbin (100) for a transformer (1000) with a primary coil element (101) and a secondary coil element (102) is specified, the bobbin (100) comprising at least two primary compartments (10) configured for accommodating the primary coil element (101) formed by windings of a wire (110) that is wound around a winding axis (99), the winding axis (99) defining a longitudinal direction (91), at least one secondary compartment (20) located between the at least two primary compartments (10) along the longitudinal direction (91) and configured for accommodating a secondary winding element (120) of the secondary coil element (102), wherein the bobbin (100) is formed as a single piece, and the at least one secondary compartment (20) is configured as a slot into which the secondary winding element (120) can be mounted by sliding the secondary winding element (120) into the at least one secondary compartment (20) along a mounting direction (92) that is perpendicular to the longitudinal direction (91). Furthermore, a transformer (1000) and a method for manufacturing a transformer (1000) are specified. Significant Figure: Fig. 15

Description

[0001] Description

[0002] Bobbin for a transformer, transformer and method for manufacturing a transformer

[0003] A bobbin for a transformer is specified. Furthermore, a transformer and a method for manufacturing a transformer are specified. Preferably, the transformer can be configured for transforming a high voltage to a low voltage. Such transformers are known as so-called HVLV transformers (HVLV: high voltage low voltage) or step-down transformers.

[0004] HVLV transformers are known that comprise a primary coil element formed by a wire and a secondary coil element comprising copper sheet parts forming several secondary winding parts. The secondary winding parts are mounted between individual bobbin parts that are configured to accommodate the primary winding after the copper sheet parts and the bobbin parts have been assembled. Thus, the bobbin consists of multiple separately provided parts that have to be assembled together with the secondary winding parts, for instance by snap fit connections. Consequently, the bobbin with the secondary coil element is assembled along a longitudinal direction which is also the winding axis of the primary coil element. In order to ensure a proper alignment of the secondary winding parts and the bobbin parts, pins or other alignment elements must be included. Thus, the manufacture of the bobbin parts and the assembling of the bobbin parts with the secondary winding parts is technically and timely demanding.

[0005] At least one object of particular embodiments is to provide a bobbin for a transformer. Further objects of particular embodiments is to provide a transformer and a method for manufacturing a transformer.

[0006] These objects are achieved by sub ect-matters and a method according to the independent claims. Advantageous embodiments and developments of the subject-matters and the method are characterized in the dependent claims and are also disclosed by the following description and the drawings.

[0007] According to at least one embodiment, a bobbin for a transformer is provided. According to at least one further embodiment, a transformer comprising the bobbin is provided. According to at least one further embodiment, a method for manufacturing the transformer with the bobbin is provided. Features and embodiments described herein equally apply to the bobbin, to the transformer and to the method for manufacturing the transformer.

[0008] According to a further embodiment, the bobbin is formed as a single piece. In particular, this can mean that the bobbin is not formed by two or more parts that are manufactured as separate parts and then assembled afterwards. Preferably, the bobbin comprises or is made from a plastic material, for instance PBT (polybutylene terephthalate) or PA (polyamide) , wherein the plastic material can be glass-fiber reinforced. Preferably, the bobbin is completely made from glass-fiber reinforced PBT. The bobbin can preferably be provided by being manufactured in a three-dimensional printing process.

[0009] According to a further embodiment, the transformer comprises a primary coil element and a secondary coil element. Each of the primary coil element and secondary coil element comprises at least one and preferably a plurality of windings that is / are mounted on the bobbin . Preferably, the trans former is configured as a HVLV trans former, so that the primary coil element can comprise nl windings and the secondary coil element can comprise n2 windings with nl > n2 .

[0010] According to a further embodiment , the bobbin comprises at least two primary compartments configured for accommodating the primary coil element . The primary coil element is preferably formed by windings of a wire that is wound around a winding axis . In particular, the winding axis defines a longitudinal direction . The at least two primary compartments are arranged along the longitudinal direction and are preferably separated from each other . Thus , the primary coil element comprises at least two primary coil element parts that are arranged in at least two separate regions defined by the at least two primary compartments . The wire forming the primary coil element can be wound as a single wire with at least one winding in each primary compartment , so that each of the primary coil element parts comprises at least one winding, wherein the primary coil element parts are connected in series by the coil wire .

[0011] According to a further embodiment , the bobbin comprises at least one secondary compartment located between the at least two primary compartments along the longitudinal direction . The at least one secondary compartment is configured for accommodating a secondary winding element of the secondary coil element . In particular, the at least one secondary compartment is configured as a slot into which the secondary coil element can be mounted by sliding the secondary winding element into the at least one secondary compartment along a mounting direction that is perpendicular to the longitudinal direction . Consequently, the primary coil element can be formed by winding a wire , whereas the secondary coil element can be formed by at least one secondary winding element that is slid, along a direction perpendicular to the longitudinal direction, into a slotted region of the bobbin forming the at least one secondary compartment .

[0012] Furthermore , the bobbin can comprise a plurality of primary compartments and a plurality of secondary compartments . Preferably, the primary compartments and the secondary compartments are arranged along the longitudinal direction in an alternating arrangement . Preferably, the number of primary compartments is equal to the number of secondary compartments . In another preferred embodiment it can also be possible that the number of primary compartments is one more than the number of secondary compartments . In case the bobbin comprises a plurality of primary compartments and a plurality of secondary compartments , the trans former can comprise a plurality of secondary winding elements , wherein each of the secondary winding elements is mounted in one of the secondary compartments in the manner described above , i . e . , by sliding the secondary winding element into one of the secondary compartments along the mounting direction . The features and embodiments described above and below for at least one secondary compartment and for a secondary winding element preferably apply to all secondary compartments of the bobbin and to all secondary winding elements of the trans former, respectively . In particular, all secondary winding elements of the secondary coil element can be embodied similar to each other and can be manufactured as individual parts that are individually mounted on the bobbin in the described manner .

[0013] In case the trans former comprises a plurality of secondary winding elements , the secondary winding elements are preferably connected in parallel by two connection elements . In particular, the connection elements can be arranged next to the bobbin and can be fixed only to the secondary winding elements , for instance by clamping and / or a solder connection . Alternatively, a connection of the secondary winding elements in series is also possible .

[0014] According to a further embodiment , the bobbin comprises an opening reaching through the bobbin along the longitudinal direction . Preferably, the opening is configured for at least partly accommodating at least a part of a core element . Consequently, according to preferred embodiments the trans former comprises the bobbin, a primary coil element accommodated in the at least two primary compartments , a secondary coil element comprising a secondary winding element accommodated in the at least one secondary compartment and a core element comprising a core part that is accommodated in an opening reaching into and / or through the primary and secondary coil element along the longitudinal direction . Consequently, according to a preferred embodiment , in the method for manufacturing the trans former the bobbin is provided, the secondary winding element is slid into the at least one secondary compartment along the mounting direction, the primary coil element is formed in the at least two primary compartments by winding a wire around the winding axis , and the core part of the core element is slid into the opening reaching into and / or through the primary and secondary coil element along the longitudinal direction .

[0015] According to a further embodiment , the core element can comprise or be made of a ferromagnetic material and can furthermore comprise or be formed as at least one PQ core . Preferably, the core element is formed as two PQ cores , wherein each of the two PQ cores has a core part that is inserted into the opening from di f ferent sides of the bobbin along the longitudinal direction, so that the core element can at least partly enclose the bobbin .

[0016] According to a further embodiment , the at least two primary compartments and the at least one secondary compartment surround the opening, so that the primary coil element and the secondary coil element each at least partly surround the opening and, thus , a part of the core element when installed in the trans former .

[0017] In particular, each of the at least two primary compartments can comprise a bottom surface formed as a lateral cylinder surface facing away from the opening and surrounding the opening . Thus , in a sectional view with a viewing direction along the longitudinal direction, the bottom surface can form a circle around the opening .

[0018] Furthermore , the at least one secondary compartment can comprise two slits that are arranged opposite to each other along a transversal direction that is perpendicular to both the longitudinal direction and the mounting direction . In particular, the two slits can be connected to the opening . The at least one secondary compartment can comprise a bottom surface facing away from the opening and being at least partly interrupted by the slits . Preferably, the bottom surface of the at least one secondary compartment can, in particular, be substantially formed as a U shape , which means that , in a sectional view with a viewing direction along the longitudinal direction, the bottom surface appears substantially as a U that is interrupted by the slits . According to a further embodiment , the secondary winding element comprises a winding region and two contact regions , wherein the winding region can preferably partly encompass the opening in the bobbin . In particular, the winding region can partly be accommodated on the bottom surface of the secondary compartment . When mounted on the bobbin, the two contact regions can preferably proj ect from the bobbin along the mounting direction . Furthermore , the two contact regions can have , along the transversal direction, a distance to each other that is smaller than a width of the opening along the transversal direction . When the secondary winding element is slid into the secondary compartment , the connection elements can partly move through the slits so that the secondary winding element is not blocked when being slid into the secondary compartment .

[0019] Furthermore , the secondary winding element can comprise a heat dissipating region located at a side of the winding region remote from the two contact regions . When mounted on the bobbin, the heat dissipating region, which can be formed as a region that is bent with respect to the winding region and the contact regions , can protrude from the bobbin on a side opposite to the contact regions .

[0020] Preferably, the secondary winding element can be a metal sheet . The metal can be or comprise copper or a copper alloy . The secondary winding element can be manufactured, for instance , from a metal sheet that is etched and / or stamped and that is , i f necessary, bent to result in the shape of the secondary winding element .

[0021] According to a further embodiment , the at least one secondary compartment comprises at least one fastening element configured for fastening the secondary winding element in the at least one secondary compartment . Preferably, the at least one fastening element is a hook element . Furthermore , the secondary winding element can comprise at least one fastening region forming a snap j oint with the at least one fastening element of the at least one secondary compartment . The fastening region can be a ledge , protrusion or opening having a surface with which the fastening element of the at least one secondary compartment can engage . Thus , when the secondary winding element is slid into the secondary compartment and reaches its predetermined final position, the secondary winding element can be held in place by the snap oint .

[0022] According to a further embodiment , the at least one secondary compartment comprises at least one alignment element configured for interacting with an alignment region of the secondary winding element . Consequently, the secondary winding element can comprise an alignment region that interacts with the alignment element located in the secondary compartment . For instance , the alignment region can be an indentation and the alignment element can be a protrusion fitting into the indentation or vice versa .

[0023] According to preferred embodiments , the bobbin and the trans former are configured as follows . The trans former is preferably a HVLV trans former that can comprise sheet-copper-stamped secondary winding elements . The secondary winding elements can be several sheet metal parts connected to each other in parallel , thereby forming the secondary coil element . A litz wire forming the windings of the primary coil element can be routed in-between the secondary winding elements . The bobbin is embodied as a single piece and has primary compartments for the windings of the primary coil element and secondary compartments for the secondary winding elements of the secondary coil element , wherein the primary compartments and the secondary compartments are preferably arranged in an alternating manner . The secondary compartments are formed as slots that are accessible , for installing the secondary winding elements , from the mounting direction that is perpendicular to the winding axis of the primary coil element .

[0024] Consequently, as described above , it is not necessary to use a bobbin comprising several separate parts that have to be assembled, since the secondary winding elements can be arranged on the bobbin by sliding the secondary winding elements into the slot-shaped secondary compartments along a direction perpendicular to the direction of the winding axis of the primary coil element . This leads to a faster assembly of the trans former and limits the number of parts used for the final product compared to a multi-part bobbin . In particular, the secondary winding elements can be assembled before the core element is assembled . The secondary winding elements easily slide through the slot-shaped secondary compartments with the slits , and then are snapped into the bobbin by means of the fastening elements and fastening regions . This leads to higher robustness of the complete device and to fewer assembly steps . A multiple-piece bobbin with a snap-in construction as known in the prior art is no longer needed . This will increase the robustness for mechanical quali fication such as vibration and so on, as snap-in parts can lead to failure modes .

[0025] Further features , advantages and expediencies will become apparent from the following description of exemplary embodiments in conj unction with the figures . Figure 1 shows a schematic illustration of a method for manufacturing a trans former according to an embodiment ,

[0026] Figures 2 to 7 show schematic illustrations of a bobbin according to a further embodiment ,

[0027] Figures 8 to 16 show schematic illustrations of a trans former and of components of the trans former according to a further embodiment .

[0028] In the embodiments and figures , identical , similar or identically acting elements are provided in each case with the same reference numerals . The elements illustrated and their si ze ratios to one another should not be regarded as being to scale , but rather individual elements , such as for example layers , components , devices and regions , may have been made exaggeratedly large to illustrate them better and / or to aid comprehension .

[0029] In connection with the figures , preferred exemplary embodiments of a bobbin 100 , a trans former 1000 and a method for manufacturing the trans former 1000 are described in the following . However, the described preferred embodiments and their features are not to be understood as limitations . Rather, alternatively or additionally to the features described in connection with the figures , the embodiments shown in the figures can comprise further features described in the general part of the description . Moreover, features and embodiments of the figures can be combined with each other, even i f such combination is not explicitly described . Figure 1 shows a method for manuf cturing a trans former 1000 as indicated in Figure 16 comprising a bobbin 100 as shown in Figures 2 to 7 . In particular, Figures 2 to 5 show various three-dimensional views of the bobbin 100 , Figure 6 shows a transparent three-dimensional view of the bobbin 100 and Figure 7 shows a detail of the bobbin 100 in a sectional view . Figures 8 to 15 show various views of components and of various states of the manufacturing process of the trans former 1000 . A longitudinal direction 91 , a mounting direction 92 and a transversal direction 93 as defined in the following are indicated in the figures for the sake of clari fication . The following description equally applies to all figures , even i f not all elements and features are indicated by reference signs in all figures .

[0030] In a first step 1 of the method for manufacturing the trans former 1000 , the bobbin 100 is provided . The bobbin 100 has , in particular, at least two primary compartments 10 configured for accommodating a primary coil element 101 and at least one secondary compartment 20 located between the at least two primary compartments 10 along the longitudinal direction 91 for accommodating a secondary winding element 120 of a secondary coil element 102 as indicated, for instance , in Figure 11 . In the shown preferred embodiments , the bobbin 100 comprises a plurality of primary compartments 10 and a plurality of secondary compartments 20 . By way of example , the bobbin 100 comprises four primary compartments 10 and four secondary compartments 20 that are arranged alternating with each other along the longitudinal direction 91 . However, also other numbers of primary compartments 10 and of secondary compartments 20 are possible , wherein, preferably, the primary compartments 10 and the secondary compartments 20 are arranged in an alternating arrangement . The bobbin 100 is formed as a single piece . Accordingly, the complete bobbin 100 is provided as a single piece before the other method steps of the method for manufacturing the trans former 1000 according to Figure 1 are carried out . Preferably, the bobbin 100 is not formed by two or more parts that are manufactured as separate parts and then assembled afterwards . The bobbin 100 is preferably manufactured and provided by a three-dimensional ( 3D) printing process . 3D printing allows the manufacture of the bobbin 100 as a single piece with all its features described in the following, so that preferably no further assembly steps whatsoever are necessary for providing the bobbin . The bobbin 100 comprises or is made from a plastic material , preferably PBT or PA, that can be glass- fiber reinforced . Preferably, the bobbin 100 is completely made from glass- fiber reinforced PBT .

[0031] A primary coil element 101 is formed in the primary compartments 10 in a further method step 2 . As indicated in Figure 11 , the primary coil element 101 is formed by windings of a wire 110 like a litz wire that is wound around a winding axis 99 that defines the longitudinal direction 91 .

[0032] Corresponding to the number of primary compartments 10 of the bobbin 100 , the primary coil element 101 comprises a plurality of primary coil element parts 111 that are arranged in separate regions defined by the primary compartments 10 . The wire 110 forming the primary coil element 101 can be wound as a single wire with at least one winding in each primary compartment 10 , so that each of the primary coil element parts 111 comprises at least one winding, wherein the primary coil element parts 111 are connected in series by the coil wire 110 . In the shown embodiment , the wire 110 is wound around the winding axis 99 forming a first winding in every primary compartment 10 going from primary compartment 10 to primary compartment 10 along the longitudinal direction 91 in a forward direction and then forming a second winding in every primary compartment 10 going from primary compartment 10 to primary compartment 10 along the longitudinal direction 91 in a back direction, so that in the end each primary compartment 10 accommodates two windings of the wire 110 . Consequently, in the shown embodiment the primary coil element 101 comprises four primary coil element parts 111 with two windings each, so that the primary coil element 101 has a total of eight windings . Alternatively, other numbers of windings are also possible . The parts of the wire 110 that connect the primary coil element parts 111 with each other can be accommodated in a groove 103 of the bobbin 101 .

[0033] For each of the secondary compartments 20 , a secondary winding element 120 as shown in Figure 8 is provided . For forming a secondary coil element 102 , the secondary winding elements 120 are installed in a further method step 3 as described in detail in the following . Method step 3 comprising the mounting of the secondary winding elements 120 in the secondary compartments 20 can be carried out before or after method step 2 of forming the primary coil element 101 .

[0034] The secondary winding elements 120 are made from metal sheets that are etched and / or stamped and, i f necessary, bent to result in the desired shape that is explained in detail below . The metal of the secondary winding elements 120 can be or comprise copper or a copper alloy .

[0035] Each of the secondary compartments 20 is configured for accommodating a secondary winding element 120 of the secondary coil element 102 . In particular, each of the secondary compartments 20 is configured as a slot in which a secondary winding element 120 can be mounted by sliding the secondary winding element 120 into the secondary compartment 20 along the mounting direction 92 that is perpendicular to the longitudinal direction 91 and, thus , perpendicular to the winding axis 99 of the primary coil element 101 . In Figure 9 the bobbin 100 is shown with three secondary winding elements 120 already mounted and a fourth secondary winding element 120 hal f inserted in a secondary compartment 20 . Figure 10 shows a sectional view of Figure 9 corresponding to a section through a secondary compartment 20 of the bobbin with a sectional plane perpendicular to the longitudinal direction 91 . Figure 11 shows the bobbin 100 with the mounted primary coil element 101 as described above and with all secondary winding elements 120 mounted in a secondary compartment 20 .

[0036] In order to form the secondary coil element 102 , the secondary winding elements 120 are electrically connected to each other either in series or in parallel . In the shown embodiment , the secondary winding elements 120 are connected in parallel by two connection elements 104 that are shown in Figures 13 to 16 . The connection elements 104 can be made from a sheet metal similar to the sheet metal used for the secondary winding elements 120 . Since the secondary winding elements 120 are connected to each other in parallel , the secondary winding elements 120 with the connection elements 104 for a secondary coil element 102 with ef fectively a single winding . Thus , the ratio of the number of windings of the primary coil element 101 to the number of windings of the secondary coil element 102 corresponds to the number of windings of the primary coil element 101 and, thus , is 8 to 1 in the shown embodiment 1 . The connection elements 104 are arranged next to the bobbin 100 above the groove 104 and are fixed to the secondary winding elements 120 , for instance by clamping and / or a solder connection .

[0037] In a further method step 4 of the method of Figure 1 , a core element 200 is installed . The core element 200 is installed after the secondary winding elements 120 are mounted in the secondary compartments 20 and before or after the secondary winding elements 120 are electrically connected to each other . The core element 200 comprises or is made of a ferromagnetic material . In the shown embodiment , the core element 200 is formed as two PQ cores , which partly enclose the bobbin 100 . Figures 12 to 15 show one of the PQ cores and Figure 16 shows the trans former 1000 with the completely installed core element 200 . As alternative to two PQ cores , the core element 200 can be a single PQ core having a length that corresponds to the length of the bobbin 100 along the longitudinal direction 91 . Furthermore , other core types are possible .

[0038] The bobbin 100 comprises an opening 105 reaching through the bobbin 100 along the longitudinal direction . The opening 105 is configured for accommodating a part 201 of the core element 200 . In the shown embodiment , each of the PQ cores has a core part 201 that is accommodated in the opening 105 . In the section view in Figure 12 , one of the PQ cores of the core element 200 is shown before being installed on the bobbin 100 . The core parts 201 of the two PQ cores are inserted into the opening 105 from di f ferent sides of the bobbin 100 along the longitudinal direction 91 and reach into the bobbin 100 and partly through the primary and secondary coil elements 101 , 102 along the longitudinal direction 91 , respectively . The primary compartments 10 and the secondary compartments 20 surround the opening 105 , so that the primary coil element 101 and the secondary coil element 102 each at least partly surround the opening 105 and the core parts 201 of the core element 200 when installed in the trans former 1000 .

[0039] In particular, each of the primary compartments 10 comprises a bottom surface 11 as indicated in Figure 4 , the bottom surface 11 formed as a lateral cylinder surface facing away from the opening 105 and surrounding the opening 105 . Thus , in a sectional view with a viewing direction along the longitudinal direction 91 , each of the bottom surfaces 11 forms a circle around the opening 105 .

[0040] Each of the secondary compartments 20 comprises two slits 21 that are arranged opposite to each other along the transversal direction 93 . In particular, the two slits 21 are connected to the opening 105 . The secondary compartments 20 each comprise a bottom surface 22 , as indicated in Figure 4 , facing away from the opening 105 and being at least partly interrupted by the slits 21 . Consequently, the secondary compartments 20 are connected to the opening 105 through the slits 21 . Preferably, the bottom surface 22 of each of the secondary compartments 20 is substantially formed as a U shape , so that , in a sectional view with a viewing direction along the longitudinal direction 91 , the bottom surface 22 appears substantially as a U that is interrupted by the slits 21 .

[0041] Each of the secondary winding elements 120 comprises a winding region 121 and two contact regions 122 , wherein the winding region 121 partly encompasses the opening 105 of the bobbin 100 as can be seen, for instance , in Figures 12 and 13 . In particular, the winding regions 121 are accommodated on the bottom surfaces 22 of the secondary compartments 20 . When mounted on the bobbin 100 , the two contact regions 122 proj ect from the bobbin 100 in a direction along the mounting direction 92 and are connected to the connection elements 104 . In the shown embodiment , the connection elements 104 have openings into which the contact regions 122 are inserted . The secondary coil element 102 can be electrically contacted via the connection elements 104 .

[0042] Furthermore , the two contact regions 122 have , along the transversal direction 93 , a distance to each other that is smaller than a width of the opening 105 along the transversal direction 93 , so that the winding region 121 can surround more than hal f of the opening 105 and, thus , of the core parts 201 of the core element 200 as indicated in Figure 14 which shows a view along the longitudinal direction, wherein the bobbin 100 is shown transparent , so that a secondary winding element 120 is completely visible . When a secondary winding element 120 is slid into a secondary compartment 20 , the connection elements 122 partly move through the slits 21 so that the secondary winding element 120 is not blocked by the bottom surface 22 when being slid into the secondary compartment 20 , as can be seen, for instance , in Figures 9 and 10 .

[0043] Furthermore , each of the secondary winding elements 120 has a heat dissipating region 123 located at a side of the winding region 121 remote from the two contact regions 122 . When a secondary winding element 120 is mounted on the bobbin 100 , the heat dissipating region 123 , which is formed as a region that is bent with respect to the winding region 121 and the contact regions 122 , can protrude from the bobbin 120 on a side opposite to the contact regions 122 . With the heat dissipation regions 123 of the secondary winding elements

[0044] 120 , the trans former 1000 can be mounted on a heat sink .

[0045] Furthermore , each of the secondary compartments 20 comprise two fastening elements 24 configured for fastening the respective secondary winding elementl20 mounted in the secondary compartment 20 . Preferably, the fastening elements 24 are hook elements . The secondary winding elements comprise two fastening regions 124 that are configured to form a snap j oint with the fastening elements 24 . The fastening regions 124 can be a ledge or protrusion or even an opening having a surface with which a fastening element 24 can engage . Thus , when a secondary winding element 120 is slid into a secondary compartment 20 and reaches its predetermined final position, the secondary winding element 120 can be held in place by the snap j oint formed by the fastening elements 24 and the fastening regions 124 .

[0046] In order to ensure an aligned position of each of the secondary winding elements 120 in the secondary compartments 20 , each of the secondary compartments 20 comprise an alignment element 25 configured for interacting with an alignment region 125 of a secondary winding element 120 . Consequently, each of the secondary winding elements 120 comprises an alignment region 125 that interacts with the alignment element 25 located in a secondary compartment 20 . As can be seen, for instance , in Figures 10 and 13 , the alignment region 125 can be an indentation and the alignment element 25 can be a protrusion fitting into the indentation, or vice versa . The invention is not restricted by the description on the basis of the exemplary embodiments . Rather, the invention encompasses any new feature and also any combination of features , which in particular comprises any combination of features in the patent claims , even i f this feature or this combination itsel f is not explicitly speci fied in the patent claims or exemplary embodiments .

[0047] Reference numerals

[0048] 10 primary compartment

[0049] 11 bottom surface

[0050] 20 secondary compartment

[0051] 21 slit

[0052] 22 bottom surface

[0053] 24 fastening element

[0054] 25 alignment element

[0055] 91 longitudinal direction

[0056] 92 mounting direction

[0057] 93 transversal direction

[0058] 99 winding axis

[0059] 100 bobbin

[0060] 101 primary coil element

[0061] 102 secondary coil element

[0062] 103 groove

[0063] 104 connection element

[0064] 110 wire

[0065] 111 primary coil element part

[0066] 120 secondary winding element

[0067] 121 winding region

[0068] 122 contact region

[0069] 123 heat dissipation region

[0070] 124 fastening regions

[0071] 125 alignment region

[0072] 200 core element

[0073] 1000 trans former

Claims

Patent claims1. Bobbin (100) for a transformer (1000) with a primary coil element (101) and a secondary coil element (102) , the bobbin (100) comprising:- at least two primary compartments (10) configured for accommodating the primary coil element (101) formed by windings of a wire (110) that is wound around a winding axis (99) , the winding axis (99) defining a longitudinal direction ( 91 ) ,- at least one secondary compartment (20) located between the at least two primary compartments (10) along the longitudinal direction (91) and configured for accommodating a secondary winding element (120) of the secondary coil element (102) , wherein- the bobbin (100) is formed as a single piece, and- the at least one secondary compartment (20) is configured as a slot into which the secondary winding element (120) can be mounted by sliding the secondary winding element (120) into the at least one secondary compartment (20) along a mounting direction (92) that is perpendicular to the longitudinal direction (91) .

2. Bobbin (100) according to claim 1, wherein the bobbin (100) is completely made from a plastic material.

3. Bobbin (100) according to claim 1 or 2, further comprising an opening (105) reaching through the bobbin (100) along the longitudinal direction (91) , the opening being configured for accommodating at least a part of a core element (200) .

4. Bobbin (100) according to claim 3, wherein the at least two primary compartments (10) and the at least one secondary compartment (20) surround the opening (105) .

5. Bobbin (100) according to any one of the preceding claims, wherein the at least one secondary compartment (20) comprises two slits (21) that are arranged opposite to each other along a transversal direction (93) that is perpendicular to both the longitudinal direction (91) and the mounting direction (92) .

6. Bobbin (100) according to claim 5 with reference to claim 3, wherein the two slits (21) are connected to the opening (105) .

7. Bobbin (100) according to claim 6, wherein the at least one secondary compartment (20) comprises a bottom surface (22) facing away from the opening (105) and being interrupted by the slits (21) .

8. Bobbin (100) according to any one of the preceding claims, wherein the at least one secondary compartment (20) comprises at least one fastening element (24) configured for fastening the secondary winding element (120) in the at least one secondary compartment (20) .

9. Bobbin (100) according to claim 8, wherein the at least one fastening element (24) is a hook element.

10. Bobbin (100) according to any one of the preceding claims, wherein the at least one secondary compartment (20) comprises at least one alignment element (25)configured for interacting with an alignment region (125) of the secondary winding element (120) .

11. Bobbin (100) according to any one of the preceding claims, wherein the bobbin (100) comprises a plurality of primary compartments (10) and a plurality of secondary compartments (20) that are arranged along the longitudinal direction (91) in an alternating arrangement .

12. Transformer (1000) , comprising- a bobbin (100) according to any one of the preceding claims ,- a primary coil element (101) accommodated in the at least two primary compartments (10) ,- a secondary coil element (102) comprising a secondary winding element (120) that is accommodated in the at least one secondary compartment (20) , and- a core element (200) comprising a core part (201) that is accommodated in an opening (105) of the bobbin (100) at reaching through the primary coil element (101) and the secondary coil element (102) along the longitudinal direction ( 91 ) .

13. Transformer (1000) according to claim 12, wherein the core element (200) comprises or is a PQ core.

14. Transformer (1000) according to claim 12 or 13, wherein the secondary winding element (120) comprises a winding region (121) and two contact regions (122) , wherein the winding region (121) partly encompasses the core part (201) .

15. Transformer (1000) according to any one of the claims 12 to 14, wherein the two contact regions (122) have a distance to each other along the transversal direction (93) that is smaller than a width of the opening (105) along the transversal direction (93) .

16. Transformer (1000) according to any one of the claims 12 to 15, wherein the secondary winding element (120) comprises at least one fastening region (124) forming a snap joint with a fastening element (24) of the at least one secondary compartment (20) .

17. Transformer (1000) according to any one of the claims 12 to 16, wherein the transformer (1000) comprises a plurality of secondary winding elements (120) that a connected in parallel by two connection elements (104) .

18. Transformer (1000) according to any one of the claims 12 to 17, wherein the secondary winding element (120) comprises an alignment region (125) that interacts with an alignment element (25) located in the secondary compartment (20) .

19. Method for manufacturing a transformer (1000) according to any one of the claims 12 to 18, wherein- the bobbin (100) according to any one of the claims 1 to 11 is provided,- the secondary winding element (120) is slid into the at least one secondary compartment (20) along the mounting direction ( 91 ) ,- the primary coil element (101) is formed in the at least two primary compartments (10) by winding a wire (110) around the winding axis (99) ,- the core part (201) of the core element (200) is slid into the opening (105) , so that the core part (201) reaches into and / or through the primary coil element (101) and the secondary coil element (102) along the longitudinal direction (91) .

20. Method according to claim 19, wherein the bobbin (100) is manufactured and provided by a three-dimensional printing process.

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